Information injection-pump assembly
BOSCH
9 400 613 491
9400613491
ZEXEL
101401-4571
1014014571
ISUZU
8971140060
8971140060
Rating:
Service parts 101401-4571 INJECTION-PUMP ASSEMBLY:
1.
_
6.
COUPLING PLATE
7.
COUPLING PLATE
8.
_
9.
_
11.
Nozzle and Holder
8-97114-017-0
12.
Open Pre:MPa(Kqf/cm2)
18.1{185}
15.
NOZZLE SET
Cross reference number
BOSCH
9 400 613 491
9400613491
ZEXEL
101401-4571
1014014571
ISUZU
8971140060
8971140060
Zexel num
Bosch num
Firm num
Name
9 400 613 491
8971140060 ISUZU
INJECTION-PUMP ASSEMBLY
4HF1 K 14BC INJECTION PUMP ASSY PE4A,5A, PE
4HF1 K 14BC INJECTION PUMP ASSY PE4A,5A, PE
Calibration Data:
Adjustment conditions
Test oil
1404 Test oil ISO4113 or {SAEJ967d}
1404 Test oil ISO4113 or {SAEJ967d}
Test oil temperature
degC
40
40
45
Nozzle and nozzle holder
105780-8140
Bosch type code
EF8511/9A
Nozzle
105780-0000
Bosch type code
DN12SD12T
Nozzle holder
105780-2080
Bosch type code
EF8511/9
Opening pressure
MPa
17.2
Opening pressure
kgf/cm2
175
Injection pipe
Outer diameter - inner diameter - length (mm) mm 6-2-600
Outer diameter - inner diameter - length (mm) mm 6-2-600
Overflow valve
131424-4920
Overflow valve opening pressure
kPa
127
107
147
Overflow valve opening pressure
kgf/cm2
1.3
1.1
1.5
Tester oil delivery pressure
kPa
157
157
157
Tester oil delivery pressure
kgf/cm2
1.6
1.6
1.6
Direction of rotation (viewed from drive side)
Left L
Left L
Injection timing adjustment
Direction of rotation (viewed from drive side)
Left L
Left L
Injection order
1-3-4-2
Pre-stroke
mm
4.1
4.05
4.15
Rack position
Point A R=A
Point A R=A
Beginning of injection position
Governor side NO.1
Governor side NO.1
Difference between angles 1
Cal 1-3 deg. 90 89.5 90.5
Cal 1-3 deg. 90 89.5 90.5
Difference between angles 2
Cal 1-4 deg. 180 179.5 180.5
Cal 1-4 deg. 180 179.5 180.5
Difference between angles 3
Cyl.1-2 deg. 270 269.5 270.5
Cyl.1-2 deg. 270 269.5 270.5
Injection quantity adjustment
Adjusting point
-
Rack position
12.6
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
75.4
73.8
77
Max. variation between cylinders
%
0
-4
4
Basic
*
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_02
Adjusting point
H
Rack position
9.8+-0.5
Pump speed
r/min
285
285
285
Average injection quantity
mm3/st.
15.5
14.2
16.8
Max. variation between cylinders
%
0
-10
10
Fixing the rack
*
Standard for adjustment of the maximum variation between cylinders
*
Injection quantity adjustment_03
Adjusting point
A
Rack position
R1(12.6)
Pump speed
r/min
1100
1100
1100
Average injection quantity
mm3/st.
75.4
74.4
76.4
Basic
*
Fixing the lever
*
Injection quantity adjustment_04
Adjusting point
B
Rack position
R1+0.2
Pump speed
r/min
1600
1600
1600
Average injection quantity
mm3/st.
86.3
82.3
90.3
Fixing the lever
*
Injection quantity adjustment_05
Adjusting point
I
Rack position
-
Pump speed
r/min
150
150
150
Average injection quantity
mm3/st.
80
80
112
Fixing the lever
*
Timer adjustment
Pump speed
r/min
1375--
Advance angle
deg.
0
0
0
Remarks
Start
Start
Timer adjustment_02
Pump speed
r/min
1325
Advance angle
deg.
0.3
Timer adjustment_03
Pump speed
r/min
1500
Advance angle
deg.
3.3
2.8
3.8
Timer adjustment_04
Pump speed
r/min
1600--
Advance angle
deg.
5
4.5
5.5
Remarks
Finish
Finish
Test data Ex:
Governor adjustment
N:Pump speed
R:Rack position (mm)
(1)Torque cam stamping: T1
(2)Tolerance for racks not indicated: +-0.05mm.
----------
T1=H96
----------
----------
T1=H96
----------
Speed control lever angle
F:Full speed
I:Idle
(1)Stopper bolt set position 'H'
----------
----------
a=41deg+-5deg b=35deg+-3deg
----------
----------
a=41deg+-5deg b=35deg+-3deg
Stop lever angle
N:Pump normal
S:Stop the pump.
(1)Use the hole at R = aa
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
----------
aa=64mm
----------
a=20deg+-5deg b=29deg+-5deg
0000001501 FICD
(A) applied negative pressure
(B) Screw
(c) Nut
1. Set the actuator as described below.
(1)Confirm that there is clearance between the actuator lever and the speed lever.
(2)Loosen the nut (C).
(3)Push in the screw (B).
(4)Apply P1 from the actuator (A) part.
(5)Pull out the screw (B) slowly.
(6)Tighten and fix the nut (C) when pump speed is Na and the rack position is Ra.
(7)Torque the nut (C) to T1.
(8)Apply P2 several times.
(9)Confirm that the actuator functions normally.
(10)Confirm that there is a clearance between the actuator lever and the speed lever at that time.
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=440r/min Ra=9.2+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm
----------
P1=53.3kPa(400mmHg) P2=53.3kPa(400mmHg) Na=440r/min Ra=9.2+-0.1mm T1=1.2~1.6N-m(0.12~0.16kgf-m)
----------
L=(5)mm
Timing setting
(1)Pump vertical direction
(2)Position of gear's standard threaded hole at No 1 cylinder's beginning of injection
(3)Stamping position on the A/T outer rim
(4)Pump bracket check hole position.
(5)At the No 1 cylinder's beginning of injection, align with the projection seen through the bracket's check hole and mark the A/T's bevel C1.
(6)B.T.D.C.: aa
----------
aa=10deg
----------
a=(60deg) b=(85deg)
----------
aa=10deg
----------
a=(60deg) b=(85deg)
Information:
Stopping the engine immediately after it has been working under load can result in overheating and accelerated wear of the engine components. Allow the engine to engine cool down before stopping. Avoiding hot engine shutdowns will maximize turbocharger shaft and bearing life.
If the engine has been operating at high load, run at low idle for at least three minutes before stopping. This cool down will reduce and stabilize internal engine coolant and oil temperatures before stopping the engine.If the engine has been operating at low loads, run the engine at low idle for 30 seconds before stopping.Make sure the shutoff procedure is understood. Refer to the Stopping the Engine instructions in the Generator Set Control Panel topic in this publication. Use the following general guidelines for stopping the engine.1. Open the Main electrical circuit breaker/Remove load from engine.2. Move the governor control to no more than half engine speed. Run the engine for three to five minutes.3. Reduce the engine speed to low idle.4. The engine may be stopped by using the Woodward Governor (if equipped), the Mechanical Governor (if equipped), or the solenoid shutoff switch.Woodward Actuator (If Equipped)
If equipped with a Woodward Actuator, move the control lever upward or forward, depending on the installation. Hold the lever to the OFF or STOP position until the engine stops.Mechanical Governor Control
A manual shutoff lever is provided to shut off the fuel from the fuel injection pump and override the governor control. The manual shutoff lever is located on the side of the pump.The engine can be shut OFF by rotating and holding the manual shutoff lever in the clockwise (CW) direction. If equipped with a Mechanical Governor Control, to move control to the SHUT OFF position: pull upward on the vernier hand grip while pushing down on thumb button. This shutdown will only move the fuel control linkage (rack) to the FUEL-OFF position. This does not shut off the air inlet.Solenoid Shutoff
Move the Control Panel Engine Control Switch (ECS, if equipped) to the STOP position.After Stopping the Engine
1. Fill the fuel tank to prevent accumulation of moisture in the fuel.2. Check the coolant level. Maintain the cooling system to 13 mm (1/2 inch) from bottom of the fill pipe. If freezing temperatures are expected, allow the radiator and engine jacket water system to cool, then check the coolant for proper antifreeze protection. The cooling system must be protected against freezing to the lowest expected ambient (outside) temperature. Add the proper coolant and water mixture if necessary.3. Check the crankcase oil level. Maintain the oil level between the ADD and FULL marks in the FULL RANGE zone on the dipstick.4. Repair any leaks, perform minor adjustments, tighten loose bolts, etc. 5. Note the service hour meter reading. Perform periodic maintenance as instructed in the Maintenance Schedule.